Closed Mould Net Shape Processing of Prepregs with Resin Injection

Abstract

High performance composite parts require strict tolerances in all directions before the parts are ready to be used. Numerous of machining and assembly operations are often required to obtain the desired geometry and tolerances. New methods to acquire advanced geometry and tight tolerances are desired to minimize the numbers of assembly and machining operations.A new closed mould technique utilizing carbon fibre prepreg materials and resin injection has been tested and evaluated. A rig implementing the closed mould tech- nique was built and used to produce generic parts. Additionally numerical analyses were run in order to understand results of the tests. The parts obtained were also subjected to a three point bending test. Carbon fibre parts without surface flaws or internal voids were achieved when the right precautions were taken. The closed mould technique presented in this thesis will greatly minimize the numbers of ma- chining operations necessary to obtain a high performance composite part. By resin injection and correct pre mould handling of the materials high quality parts are obtained.